Substations - Program 37

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Substations - Program 37

Program Overview

Program Description

This program helps substation owners enhance safety, reliability, equipment life, and performance despite shrinking maintenance budgets. It offers a complete portfolio of tools and technologies such as transformer monitoring. The program also includes resources such as failure databases and aging models to improve transformer and circuit breaker life management. It may also help operations and maintenance (O&M) engineers extend equipment life, optimize maintenance costs, and reduce outages.

Research Value

With the knowledge acquired through this research program, program members will gain access to information that can help them accomplish the following:

• Extend equipment life with maintenance guidelines

• Reduce maintenance costs via condition-based maintenance • Reduce losses via improved sulfur hexafluoride (SF6) management • Implement predictive maintenance practices for reduced outages • Prevent failure of critical transformers

Approach

EPRI substation research will yield a variety of beneficial data and knowledge to program members. This information will be delivered in a number of forms and is expected to include the following:

• Component aging models

• Equipment diagnostic and risk assessment tools and software • Maintenance best practice guidelines

• Reference books, guidelines, and field guides • Development of solid-state devices

• Industry-wide failure databases

• Collaborative environments for sharing near misses and best practices Accomplishments

In the past, the substations program has delivered valuable information that has helped its members and the industry. Some examples are listed below.

PTLOAD: Development of Algorithms to Include New Research Data on Loss of Life

• Transformer insulation life depends largely on temperature, moisture, and oxygen. A research project investigated the combined effects of temperature, moisture, and oxygen on transformer insulation aging. From experiments, curves of acceleration factor under five moisture levels at low oxygen were obtained and made available in early 2008. To effectively incorporate the results into the aging calculation of PTLOAD software, a new aging model that accounts for the combined effects of temperature and moisture is proposed.

SF6 Complete Library, Version 2.0

• The SF6 (Sulfur Hexafluoride): Computer-Based Training Modules, Version 2.0, are a set of four CDs for computer-based training on SF6 safety, handling, and analysis that include the impact of SF6 on the environment.

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Guidelines for Applications and Analysis of Transformer Industry Database (IDB) - Data and Models • Most utilities are interested in better understanding and projecting transformer service life to help manage

risk; however, generic reliability data are inadequate for today's decision support needs. A single company's data may not be sufficiently extensive nor represent statistically diverse asset population subsets. Therefore, this project's database efforts emphasize, but are not limited to, life analysis and better understanding of failure rates as a function of age and other parameters.

Guidelines for the Life Extension of Substation Equipment

• This report presents the results of an effort to establish the evolving industry needs for an updated chapter on high-voltage circuit breakers for the EPRI report, Guidelines for the Life Extension of

Substations: 2002 Update (1001779), also known as the Substation Equipment Life Extension Guidelines (LEG). The effort included an assessment undertaken to document current power circuit breaker asset management and maintenance practices, in order to identify utility needs that could be better supported through updated LEG chapters.

Current Year Activities

In the coming year, the Substations program expects to accomplish these objectives: • Transformer and circuit breaker aging models

• Transformer reference book (Copper Book)

• Transformer diagnostic and risk assessment tools and software • Substation life-extension guidelines

• Circuit breaker life management and lubrication • Development of fault current limiters to the 69 kV level • Circuit breaker diagnostics using relay data

• Fault current management and substation grounding best practices • Switching safety and reliability conference and practice sharing • Management of legacy relays and integration of the next generation Estimated 2010 Program Funding

$5.0M

Program Manager

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Summary of Projects

PS37A Transformer Life Management (056064)

Project Set Description

This project set remains the greatest single focus within the Substations program. It addresses management of the aging population of power transformers and load tap changers (LTCs) from the aspect of diagnostics, monitoring, and online condition assessment. Recently, the project set has been expanded to include the design aspects relating to geomagnetically induced currents (GICs) within transformers. Even if GIC is not currently a key concern for a company, the focus on design provides invaluable insights that will help it with future transformer specifications.

Project Number Project Title Description

P37.001 Transformer End-of-Life and Condition Assessment

Effective transformer life management via novel condition-monitoring techniques and new algorithms for turning that condition monitoring data into actions.

P37.002 Transformer Life Extension This project provides a mix of field tools and forensics analysis to extend transformer life and improve decisionmaking on these critical substation devices.

P37.001 Transformer End-of-Life and Condition Assessment (062154)

Key Research Question

There is an increasing need for electricity companies to use assets to the fullest while maintaining system reliability. In this environment, management of the aging population of power transformers has become the most critical issue facing today's substation managers and engineers. Central to transformer management is effective transformer diagnostics, condition assessment, and knowledge retention and transfer. This project addresses these key issues through three focused themes and a multiyear plan of tasks to support those themes.

Approach

Three broad themes guide the research:

1) EPRI Power Transformer Guidebook Development

2) Develop and Demonstrate New Condition Monitoring Sensors and Techniques

3) Develop and Demonstrate Tools to Convert Transformer Data into Useful Information for Action

Each year, results are delivered through tasks performed to address each theme. The stability in the themes supports a clear multiyear plan approach. Members have two distinct areas of influence on the multiyear plan: in the selection of themes and in the prioritization of the annual tasks that support these themes.

The themes that steer this project are described in detail below: Copper Book (EPRI Power Transformer Guidebook) Development

In 2010 we plan to add four chapters to the Copper Book. In each year of development, the work-to-date is published to allow members to use the materials as they are produced. The ultimate goal is a comprehensive reference book that can be used by members responsible for all aspects of transformer operation,

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maintenance, procurement, and life-cycle management. It can be used as a training aid and as a repository for all pertinent information on transformer ownership. The electronic version includes applets that perform some of the more common calculations necessary for transformer management.

Develop and Demonstrate New Condition Monitoring Sensors and Techniques

Under this theme EPRI conducts vital research on improved techniques for assessing transformer condition . The research develops new transformer diagnostic tools and evaluates existing hardware and software for transformer and LTC condition assessment. The project develops specialized sensor hardware to provide insights into transformer health that are not obtainable using traditional techniques. Develop and Demonstrate Tools to Convert Transformer Data into Useful Information for Action

Under this theme EPRI uses the knowledge and experience of the world's leading transformer engineers to develop diagnostic algorithms and expert system modules to convert transformer monitoring data into useful information for action. The results address the need that staff face in distilling large volumes of monitoring data into clear maintenance or planning actions. EPRI’s results will be produced in a way that enables companies to easily and rapidly apply the results.

Impact

• Enables effective transformer life management via condition-monitoring techniques and their application • Advances detection and analytical techniques for evaluation of partial discharges, acoustic emissions,

vibration, and dissolved gasses in oil in transformers and LTCs for better decisionmaking

• Through the Copper Book, this project produces the first comprehensive collection of transformer knowledge designed specifically for utility owners and operators

How to Apply Results

Substation engineers, designers, and operations and maintenance personnel can use this project's results to obtain complete information about the condition of a transformer, enabling them to make decisions on the disposition of transformers without additional consultation, testing, and analysis. Results will take the form of hardware, software, and guidebooks. The Copper Book will be a comprehensive reference book that can be used by utility personnel responsible for all aspects of transformer operation, maintenance, procurement, and life-cycle management. It will be used as a training aid and as a repository for all pertinent information on transformer ownership. The electronic version will include applets that will be used to perform some of the more common calculations necessary for transformer management.

2010 Products

Product Title & Description Planned

Completion Date Product Type Novel Sensors for Transformer Diagnosis: This product will consist of

research into novel sensors that return critical data from transformers. 12/31/10

Technical Update

EPRI Copper Book Development (Power Transformer Guidebook): In

2010 we will add four more chapters to the Copper Book. 12/31/10

Technical Update

Tools to Convert Transformer Data into Action: EPRI will continue to

develop diagnostic algorithms and expert system modules to convert transformer monitoring data into useful information for action.

12/31/10 Technical Update

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Future Year Products

Completion Date Product Type

Field validation results from transformer algorithm development Technical

Update

Novel Sensors for Transformer Diagnosis - field data gathering 12/31/11 Technical

Update

EPRI Copper Book Development - Additional Chapters 12/31/11 Technical

Update

P37.002 Transformer Life Extension (058559)

A structured life extension program can help energy companies make informed decisions on maintenance, replacement or refurbishment, and operating practices to ensure safe, reliable, and cost-effective transformer use.

Approach

This project has three broad themes in Transformer Life Extension that guide the research:

1) Research into new markers in the oil, to improve estimates of remaining life.2) Application of novel online filtration materials and techniques to extend life.

3) Development of a forensic library to better predict future failures in an aging transformer fleet. Each year results are delivered through tasks performed under each theme. The stability in the themes supports a clear, multiyear plan approach.

The themes that steer this project are described in detail below: Research into new markers in the oil, to improve estimates of remaining lifeImproved estimates of a transformer's remaining life offer significant financial and reliability benefits. EPRI is researching new markers in the oil that hold the potential for large improvements in the accuracy of paper life estimates. The research has progressed from paper studies through to laboratory trials. In 2010 research will move to the first of the field pilots.

Application of novel online filtration materials and techniques

New research has demonstrated the possibility for online filtration of oxygen and moisture without the need for cartridge replacements. In 2010 EPRI research will take the successes gained in the laboratory into the field for the first pilot trials on member transformers.

Forensics Library

EPRI research examines failed units that have aged to full maturity (i.e., excluding design, materials, or workmanship flaws). The resulting forensics library provides members with new insights into likely end-of-life scenarios for the increasing population of aging transformers. Each forensic study includes both the physical evidence of the internal inspection and the life history of the unit (including historical test information,

monitored data, and loading). EPRI’s collaborative approach to this research will bring multiple members’ forensics to the study—allowing for a far more rapid development of typical failure and aging mechanisms. Presently these valuable lessons are often lost after a unit is retired. EPRI’s research in this area will capture and share this vital knowledge. This multiyear effort will be paced by access to transformer failures and historical data. Each year will produce an updated library based on all prior investigations.

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Impact

The impacts of this research include the following:

• Improved estimates of the remaining life in transformers

• Extended transformer life through application of novel filtration materials and techniques • New insights into likely end-of-life scenarios for the increasing population of aging transformers • Improved decision making on replacement or refurbishment of transformers

The research results have been structured to allow for ready application by members. In the case of the online filtration research, EPRI is demonstrating the results through pilots in member substations. The results are shared with the broader membership, and the feedback is being incorporated into refined approaches. In the case of the forensics library, the results will be made available in an easily searchable format that will enable members to focus in rapidly on the forensic studies that directly relate to their particular situations. 2010 Products

Completion Date Product Type Novel techniques to both estimate and extend transformer life: Building

on earlier research, EPRI will move to the field to pilot of new techniques for accurately estimating transformer paper life based on novel tracer

compounds in the oil.

Forensics Library: Assessments of aged transformers: The Forensics

Library will provide new and valuable insights into end-of-life scenarios for the increasing population of aging transformers.

Novel online filtration materials and techniques: EPRI will research, trial,

and document novel ideas for cartridge-free transformer filtration. 12/31/10

Technical Update

Product Title & Description _{Completion Date}Planned Product Type

New tracer compounds to estimate transformer life on-line 12/31/11 Technical

Update

Extension of the Forensics Library of aged transformers 12/31/11 Technical

Update

New materials for transformer insulation and cooling: laboratory

studies and early field experiences 12/31/11

Technical Update

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PS37B Improve Overall Substation Maintenance Management (056065)

This project set addresses substation maintenance from the top down. It starts with accepted maintenance practices and techniques. It establishes best-of-breed practices and then applies these practices to specific equipment. This, in turn, drives the required sensor, inspection, data collection, equipment models, equipment assessment, and maintenance actions. The research develops methodologies and tools to address the need for an optimized maintenance strategy. Efforts are organized in the following project areas: Life Extension, Maintenance and Condition Assessment Guidelines for Substation Equipment, Risk Mitigation and

Maintenance Strategies for Substation Equipment; Integrated Monitoring and Diagnostics; Industry Equipment Performance Database and CIM Data Standardization; and Balance of Substation - Inspection, Assessment and Maintenance Strategies. The overall strategy develops an integrated set of tools that can operate on company-wide real-time and historical data to support continuous risk and performance assessment.

P37.003 Maintenance, Condition Assessment and Life

Extension Guidelines for Substation Equipment

Provide practical reference material for integrated and consistent best practice actions for maintenance, condition assessment and life extension actions for substation equipment.

P37.004 Risk Mitigation and Maintenance Strategies for Substation Equipment

Analytics for Substations Asset Performance: Development of data models and analytics which combine condition information with fundamental understanding of the equipment to provide decision support for improved performance and risk management. P37.005 Integrated Monitoring and

Diagnostics

This project provides immediate and comprehensive knowledge of substation sensors and fast-tracks examination of new sensors from other industries in the EPRI Sensor Laboratory—allowing for confident decisionmaking on potential substation applications. P37.006 Industry-wide Equipment

Performance Database

This project builds and maintains a unique, independent repository and analysis tools to collect and analyze equipment performance data to provide information that supports maintenance and asset

management decisions. P37.007 Balance of Substation –

Inspection, Assessment and Maintenance Strategies

Balance of substation inspection, assessment and maintenance strategies

P37.003 Maintenance, Condition Assessment and Life Extension Guidelines for Substation Equipment (062155)

Utility companies need to obtain maximum value from their assets—both current performance and future service life—while fully utilizing dwindling technical staff and limited financial resources. In this environment, an organization's success depends, in part, on the availability and usability of up-to-date knowledge, data, procedures, and best-of-breed or recommended practices for substation equipment maintenance, condition assessment, and life extension. New engineers, or those reassigned to different job functions, face a steep learning curve in developing and implementing a substation equipment maintenance and asset management program. Time-constrained maintenance personnel and asset managers need to quickly locate and access the know-how and procedures stored in the industry's collective memory. Much valuable information is subject to loss upon the retirement or departure of experienced personnel.

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Cost-effectively developing a user-friendly, easily updatable reference source requires addressing the following questions:

• How to capture key knowledge that utilities would lose as a result of an aging workforce?

• How to capture the industry’s best practices in inspection, monitoring, maintenance, and equipment diagnostics?

• How to organize a self-learning repository for new hires and employees in transition? • How to ensure that the material contains the most current practice and standards? Approach

• Gather and distill information on practical aspects of equipment life extension. • Condition assessment

• Field tests

• Corrective maintenance • Develop practical reference sources for:

• Substation operations and maintenance personnel. • Task selection and resource allocation

• Engineers in transition.

• Equipment behavior and understanding techniques • Provide inputs to utility job aid and training program development.

• Develop a user group that facilitates ongoing content review, updating, and expansion.

• Enhance usability and accessibility of technical content through technology transfer activities: field guides, workshop seminars, and electronic media.

Impact

Improve Reliability and Reduce Applied O&M: Provide a readily accessible source of information that can contribute to reduced life-cycle costs while enabling improvement in the reliability of critical equipment and help optimize a maintenance program.

Knowledge Retention/Training: Provide a centralized knowledge repository to serve as an on-the-job training tool for new recruits to help them accelerate their learning in the area of substation equipment maintenance.

Knowledge Retention/Application: Offer a user-friendly and regularly updated reference support tool to help asset and maintenance personnel to carry out their work in the most cost-effective and efficient manner. How to Apply Results

Asset managers, operations and maintenance supervisors/staff, and equipment technical subject matter experts can use the results of this project to better understand and implement best practices in substation equipment life extension, maintenance, and condition assessment. The revised and updated versions of the life extension guidelines can be accessed as annually issued hard copy "color book" version and a series of field guides developed as a result of needs assessment. In addition EPRI will continue to offer workshops and services to assist utilities with implementing the practices identified in the technical reports.

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2010 Products

Completion Date Product Type New Versions of Guidelines for the Life Extension of Substation

Equipment: This guide is specifically designed to assist substation owners in

their responsibility to operate and maintain equipment. This guide helps members initiate a new maintenance, condition, and/or life extension program or refine an existing one. New sections on equipment and technologies will be added.

New Set of Pictorial Guides: These field guides will present selected

material from life extension guidelines in formats suitable for the field personnel. Many members are distributing these guides to field personnel, and they are becoming an integral component of their maintenance, condition assessment, and/or life extension program.

Maintenance, Condition Assessment, Life Extension and Diagnostics Workshop: This member workshop will expose personnel to the latest

technologies and approaches.

12/31/10

Workshop, Training, or Conference

Completion Date Product Type New Versions of Guidelines for the Life Extension of Substation

Equipment: This guide is specifically designed to assist substation owners in

their responsibility to operate and maintain equipment. This guide helps members initiate a new maintenance, condition, and/or life extension program or refine an existing one. New sections on equipment and technologies will be added.

Future On-Line E-Learning Modules, Workshop and Webcasts: On-line

self paced learning modules will continue to be developed either around maintenance or condition assessment methodologies or technologies. This software can be used with members' current learning management systems.

P37.004 Risk Mitigation and Maintenance Strategies for Substation Equipment (058560)

Best practice maintenance decisions for minimizing equipment lifecycle costs are based upon risks associated with the actual equipment condition and performance. There are four key steps involved:

understanding existing performance, understanding required performance, projecting future performance, and understanding how to bridge gaps. Ongoing R&D efforts are focused on developing condition assessment algorithms to understand existing performance for transformers and circuit breakers. This research will enhance decision making confidence and results, providing the ability to achieve the following: • Ensure optimal allocation of limited resources and selection of the most appropriate O&M tasks. • Forecast reliability and manage the risk of deferring maintenance, and identify assets that deserve more

attention in relation to others in a fleet.

• Quantify the value of performance improvements resulting from investments made in equipment monitoring, maintenance, or replacement.

• Evaluate risk moving forward (as compared to “current state” evaluation) and determine the impact of incremental dollars added or subtracted from the “current state” maintenance and investment portfolio.

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Collectively the suite of algorithms serves as the framework for Analytics for Substation Asset Performance. Approach

The approach focuses development on several key challenges: defining data requirements and availability, developing tools for risk assessment, linking risk assessments with decision support for mitigation, and tools to track and gauge the effectiveness of risk mitigation and maintenance strategy changes. Developments under proposed research include the following:

• Guidance on data collection.

• Methodologies to forecast reliability and assess risk.

• Predictive modeling techniques focused on the use of readily available data. • Methodologies to select the most appropriate actions to mitigate risk.

The basic objective for past, ongoing, and proposed research is to provide continually improved decision support methodologies primarily in the form of an integrated framework for asset risk assessment, mitigation and performance improvement – Analytics for Substations Asset Performance.

Impact

• Reduces overall maintenance costs, forecasts O&M cash flow, minimizes unplanned expenses, and maximizes the benefit/value of planned work

• Improves reliability and availability via reduced reliance on time-based maintenance by using analytics based on asset health and condition analysis to determine maintenance actions

• Enables more effective use of existing infrastructure and data and efficient use of maintenance personnel to manage operational risk

Project participants will work with a group of equipment and maintenance experts to collect pertinent data that helps define performance metrics and models for relevant equipment. Funders can then use developed algorithms, key performance indicators (KPIs), and ranking methodologies in close coordination with other equipment-focused projects. Funders can also use products to test and validate end-of-life models being pursued in other equipment-focused projects.

2010 Products

Completion Date Product Type Equipment Risk and Performance Assessment: This product provides

methodologies to help project future performance based on current condition and required future performance. It will also provide methodologies for evaluating risk mitigation measures to help select appropriate actions to achieve a desired cost and reliability, as well as other performance goals. Collectively this work will support intelligent fleet management.

Catalogue and Assessment of Industry Maintenance Best Practices for Substation Equipment: This product will catalogue and assess current

industry practices and procedures (including lessons learned by utility experts) and identify gaps and issues with existing practices. Ongoing efforts focus on key substation equipment: transformers and circuit breakers. Over time, through task force feedback and needs assessment, other substation equipment areas will be identified and added.

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Completion Date Product Type Maintenance Effectiveness Assessment: This product will be a set of

appropriate key performance indicators (KPI’s) for measuring maintenance effectiveness. It will provide guidance on how to apply, use, and track these KPI’s to improve benefits for current O&M and project incremental benefits for future O&M spending.

Completion Date Product Type Equipment Risk and Performance Assessment: This product will provide

methodologies to help project future performance based on current condition and required future performance. It will also provide methodologies for evaluating risk mitigation measures to help select appropriate actions to achieve a desired cost and reliability, as well as other performance goals. Collectively this work will support intelligent fleet management.

Catalogue and Assessment of Industry Maintenance Best Practices for Substation Equipment: This product will catalogue and assess current

industry practices and procedures (including lessons learned by utility experts) and identify gaps and issues with existing practices. Ongoing efforts focus on key substation equipment: transformers and circuit breakers. Over time, through task force feedback and needs assessment, other substation equipment areas will be identified and added.

P37.005 Integrated Monitoring and Diagnostics (058561)

Utilities are continuously seeking to improve their cost-benefit ratios by reducing the human intervention in equipment condition monitoring. Diagnostics and sensors plays a strong role. Informed decision-making on the array of sensors available—plus the true value they can provide in a substation—are difficult to quantify. This project provides the supporting industry data and research results to make these important decisions. Approach

Research in this project is built on two broad, guiding themes: Sensor awareness across multiple industries

Any utility attempting to apply sensors effectively in a substation is faced with the enormous hurdle of first accurately quantifying the entire range of sensors available and then determining how these sensors relate to the substation applications. EPRI expertise in both the sensor and substation realm have enabled the

development of a unique database that allows members to rapidly comprehend the full spectrum of options available and make efficient implementation decisions. EPRI will be publishing this database in 2010 and then updating it on a regular basis.

Cross-industry sensor research and testing

Substation diagnostics can benefit significantly from the sensor developments in other industries (e.g.,

defense, automotive, space, medical). EPRI's sensor laboratory, partnered with its substation experts, provide a unique test-bed to rapidly evaluate the potential benefits offered by these new sensors. The results will enable the utility industry to effectively gain knowledge from other industries, while the collaborative research

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on the issues will allow for cost-effective and rapid decisions though laboratory simulations that closely mirror the field.

Impact

• Immediate and comprehensive knowledge of substation sensors, currently available and under development

• Fast-track examination of new sensors from other industries in the EPRI Sensor Laboratory, allowing for confident decisionmaking on potential substation applications.

• Business case development for substation diagnostics, based on the supporting facts and field experience provided though this project

Members can apply the results through data-mining of the industry-wide sensor database. The results can help aid the development of effective business cases for substation diagnostics. Members can further validate their business decisions through the laboratory research results in the EPRI Sensor laboratory, - which is designed to closely simulate the field environment.

2010 Products

Completion Date Product Type Leverage of sensor developments from multiple industries: Through the

EPRI Sensor Laboratory and the substation expertise, new sensor technologies from other industries are rapidly evaluated for substation applications.

Industry Sensor awareness database: The database will provide members

with a searchable software tool that presents the full spectrum of commercial sensors and those in the research stage.

12/31/10 Software

Completion Date Product Type

Field trials of sensor developments from multiple industries 12/31/11 Technical

Update

2011 Industry Sensor awareness database 12/31/11 Software

P37.006 Industry-wide Equipment Performance Database (060471)

Energy companies can maximize their return on assets by ensuring that existing equipment is not replaced before it reaches the end of its “useful” life, while still maintaining reliable system operations. However, without historical performance data of assets with similar characteristics, this task can be difficult. Companies can benefit from an easily accessible repository of industry-wide equipment performance and failure data to more accurately project future performance.

Approach

This project provides members with aggregated data and information resources not currently available to individual companies, to assist in developing repair/refurbish/replace strategies for aging substation equipment fleets. The project collects equipment performance and failure data in a common format from

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many sources to establish a database that enables statistically valid analysis to determine equipment failure rates, identify “bad actors” early, and help identify best maintenance and specification practices. Data models and software applications will be developed and presented to task force advisors for comment and further refinement. Associated supplemental projects may be launched to populate the Industry-wide Equipment Performance Database (IDB) with historical data and develop company-specific applications. Transformers, tap-changers, circuit breakers and other substation equipment are included in this development.

Impact

• Improve management of existing infrastructure using pooled performance and condition-related data from all participating utilities.

• Achieve savings by using consistent data sharing and analyses based on industry common information model (CIM) standards.

• Simplify assessment of key performance indicators and metrics via automated data mining and decision-making tools.

• Enable identification of “bad actors” early, reducing unplanned outages. How to Apply Results

Using project results, participants can detect equipment risks early and implement risk-informed maintenance and asset management decisions based on industry-wide equipment performance and failure data.

2010 Products

Completion Date Product Type Equipment Performance and Failure Database – Analysis: This product

compiles and analyzes the performance and failure data of transformers, tap-changers, circuit breakers, and other substation equipment. The transformer data collection and analysis started in 2006 and now contains records on over 15,000 transformers. The circuit breaker database is under

development, with results expected to be made available in 2010.

12/31/10 Software

Equipment Performance and Failure Database – Populated Data Models: This product develops and tests data models for efficient and

effective collection of test, diagnostics, performance, and failure data, for use in industry and utility database application and performance analysis. Transformers, tap-changers, circuit breakers, and other substation equipment are included in this development.

12/31/10 Software

Guidelines for failure investigation and root cause analysis: This

technical update report will provide guidance to perform failure mode and effect analysis. The results can also be used in combination with the Equipment Performance Database and Intelligent Fleet Management methodology to manage reliability and extend life. Transformers, tap-changers, circuit breakers, and other substation equipment are included in this development.

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Completion Date Product Type New Versions: Equipment Performance and Failure Database –

Analysis: This product compiles and analyzes performance and failure data

of transformers, tap-changers, circuit breakers, and other substation equipment. The transformer data collection and analysis started in 2006 and now contains records on over 15,000 transformers. The circuit breaker database is under development, with results expected to be made available in 2010. New versions will contain results of analysis using data sets with updated (new) data.

12/31/11 Software

New Versions: Equipment Performance and Failure Database – Populated Data Models: This product develops and tests data models for

efficient and effective collection of test, diagnostics, performance and failure data for use in industry and utility database application and performance analysis. Transformers, tap-changers, circuit breakers, and other substation equipment are included in this development.

12/31/11 Software

New Versions: Guidelines for failure investigation and root cause analysis: This technical update report will provide guidance to perform

failure mode and effect analysis. The results can also be used in combination with the Equipment Performance Database and Intelligent Fleet Management methodology to manage reliability and extend life. Transformers,

tap-changers, circuit breakers, and other substation equipment are included in this development.

P37.007 Balance of Substation – Inspection, Assessment and Maintenance Strategies (065593)

Increasing the reliability, safety, and life of substation equipment requires timely and effective maintenance based on accurate inspection and knowledge of equipment condition. To achieve these objectives, personnel need to understand balance of substation equipment, their degradation and failure modes, and current industry inspection and assessment practices. Availability of new technology, coupled with a loss of institutional knowledge, heightens the challenge facing substation owners. Engineering and maintenance staffs need to remain abreast of the latest inspection developments and assessment techniques to be able to select the appropriate course for their particular circumstances. In addition, field personnel need field tools and training to ensure that correct and consistent decisions are made.

Approach

To address these issues, this project provides the following: • Needs Assessment – Balance of Substation

• Development of an R&D roadmap to identify and address outstanding issues

• Development of specific guidance for balance of substation equipment: disconnect switches (manual and motor operated), CTs, VTs, capacitor banks, and ground switches. For each of these equipment types, participants will gain the following;

• Better understanding of associated fundamental issues such as design, vintage and type issues, failure mechanisms, and degradation modes

• Ability to use this information to develop operation, maintenance, and diagnostic techniques for the associated equipment

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Impact

• Reduces overall maintenance costs, projects O&M cash flow, minimizes unplanned expenses, and maximizes the benefit/value of planned work

• Improves reliability and availability via reduced reliance on time-based maintenance by using asset health and condition analysis to determine maintenance actions

• Enables more effective use of existing infrastructure and data and efficient use of maintenance personnel to manage operational risk

Using project results, participants can detect equipment risks early and implement risk-informed maintenance and asset management decisions based on industry-wide best practices and the most advanced techniques. Results will facilitate knowledge retention and aid in training personnel.

2010 Products

Completion Date Product Type Balance of Substation Equipment – Research Needs Assessment

Roadmap: This technical update will provide results of the research needs

assessment and an R&D roadmap to identify and address outstanding issues for balance of substation equipment.

Balance of Substation – Equipment Specific Condition Assessment and Life Extension Techniques: This technical update will develop specific

guidance for balance of substation equipment: disconnect switches (manual and motor operated), CTs, VTs, capacitor banks, and ground switches. For each of these equipment types, participants will gain the following.

• Better understanding of associated fundamental issues such as design, vintage and type issues, failure mechanisms, and degradation modes • Ability to use this information to develop operation, maintenance, and

diagnostic techniques for the associated equipment.

The 2010 research will focus on disconnect switches. Future year research will address other equipment for balance of substation using a similar approach.

Completion Date Product Type Balance of Substation – Equipment Specific Condition Assessment and

Life Extension Techniques: This technical update will develop specific

guidance for balance of substation equipment: disconnect switches (manual and motor operated), CTs, VTs, capacitor banks, and ground switches. For each of these equipment types, participants will gain the following.

• Better understanding of associated fundamental issues such as design, vintage and type issues, failure mechanisms, and degradation modes • Ability to use this information to develop operation, maintenance, and

diagnostic techniques for the associated equipment.

A prioritized list of equipment will be developed working with the Task Force. Information provided in this deliverable will continue to build on the previous year's research. Future year research will address equipment for balance of substation using a similar approach.

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PS37C SF6 Environmental Management (056066)

This project set focuses on significantly improving the performance of sulfur hexafluoride (SF6)-insulated equipment. It will include providing tools to extend and estimate equipment life, reducing maintenance and operating costs of SF6 equipment, managing SF6 environmentally, and protecting the investment in SF6 -insulated equipment. Additionally, work will focus on accurately tracking the development of SF6

replacements and SF6 policy issues to provide appropriate and timely guidance on the future of SF6.

P37.008 SF6 Environmental Management and

Equipment Performance

This project helps members address SF6 issues by helping them to

improve equipment performance and safety, reduce environmental impacts, and capture and share SF6 knowledge.

P37.008 SF6 Environmental Management and Equipment Performance (052021)

Sulfur hexafluoride (SF6) is a powerful greenhouse gas with a 100-year global warming potential (GWP) of 23,900 (i.e., it is 23,900 times more powerful than carbon dioxide). Utilities face increasing pressures in the areas of SF6 emissions, safety, training, leak detection, destruction, and SF6 analysis. As pressure to reduce greenhouse gas emissions grows and cost pressures continue to escalate, energy companies need focused solutions to meet these challenges.

Approach

Three broad themes guide this project's research: 1) Reducing the impact of SF6 on the environment 2) Capturing and sharing SF6 knowledge

3) Improving the performance of SF6 insulated equipment

Each year results are delivered through tasks performed under each of the themes. The stability in the themes allows for a clear multiyear plan approach. Utility members have two distinct areas of influence on the multiyear plan: first, in the selection of themes and, second, in the prioritization of the annual tasks that support these themes.

This project provides tools and continuing research into a range of SF6 issues, including CD-based SF6 training tools, development of national and international standards to support members on SF6 issues, and training on SF6 handling, safety, and emissions reduction programs. The CD-based training tools help users retain knowledge, as well as refresh staff and educate new staff on the issues associated with SF6. This project’s research contributes important input to the national and international standards bodies, including chairing working groups and developing guides that allow for the results to enter daily utility practices. Workshops rapidly transfer practical knowledge to participants, including practical demonstrations. Impact

• Reduces costly SF6 emissions and amount of labor needed to perform regular top-ups of leaking equipment.

• Mitigates risks of potential heath hazards via safe handling techniques, tools, and guidelines. • Minimizes environmental emissions of SF6.

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• Explores alternatives to SF6.

• Enables members to stay abreast of evolving political and legislative developments. How to Apply Results

The results are designed for easy and rapid application: 1) Funders will have ready access to the CD-based SF6 training tools, with the only requirement being a PC and a printer.2) The field guide is designed as a laminated pocket guide, enabling field staff to rapidly verify critical information onsite.3) Workshop attendance enables personnel to receive hands-on training, to facilitate streamlined application of the information in the field.

2010 Products

Completion Date Product Type Pocket Field Guide for SF6 Management in a Substation - 2010

Revision: The pocket guide provides members with an updated on-site

reference of vital information on SF6 safety, handling, and analysis.

Computer-Based SF6 Training Tools - 2010 revision: The four-CD set of

training tools will be fully revised and brought up to date in the areas of SF6

safety, SF6 and the environment, SF6 handling, and SF6 analysis.

12/31/10 Assembled Package

EPRI Training and Hands-on Workshop: Workshops provide a forum for

members to become rapidly informed of the latest EPRI SF6 results while

also sharing relevant experiences.

12/31/10

Completion Date Product Type Potential replacements for SF6 (or alternatively, new SF6-free

technologies) 12/31/11

Technical Update

EPRI Training and Hands-on Workshop 12/31/11

Advanced tools for automated SF6 emissions reporting 12/31/11 Technical

Update

PS37E Switching Safety and Reliability (056068)

This project set seeks to significantly improve overall safety in substations. Participating clients have found EPRI annual conferences on power switching safety and reliability to be a very effective tool for exchanging experiences, sharing lessons learned, and keeping abreast of the latest accepted practices.

P37.011 Switching Safety and Reliability

This project aims to develop controls and procedures that prevent errors in power switching, enhance worker and public safety, and improve power delivery reliability.

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P37.011 Switching Safety and Reliability (052029)

Safety and reliability are at the top of every utility’s list of concerns and commitments. Personnel must be safeguarded as they carry out their responsibilities, and utility customers expect an uninterrupted supply of power. Switching errors must be prevented because they can create hazardous situations and unexpected power interruptions. Although some utilities have achieved very low error rates, others can benefit from further improvements.

Approach

This project conducts research with the goal of reducing switching errors, improving worker safety, reducing unscheduled outages, improving power quality, and enhancing operating efficiency and compliance with regulatory changes. It also sponsors an annual switching safety and reliability conference to transfer the research results to the utility industry. Using experts knowledgeable about the details of switching, the project analyzes data and procedures to highlight areas that might be improved and to identify industry “best

practices.” Specific goals for 2009 include the following:

• Provide an annual update on lessons learned from accidents, including near-misses. • Develop an outline of a SS&R Reference Book.

• Develop recommendations for certification of switching personnel.

• Discover weak links in switching processes, and define remedial and preventive strategies • Share “lessons learned.”

• Improve system integrity and worker safety through safe switching, safe work procedures in substations, and improved ground grids.

• Develop multimedia-based training materials.

• Monitor new industry trends and developments—such as use of high-temperature conductors, dynamic thermal circuit rating (DTCR), and increased use of work on energized lines—and develop guidelines and training materials to meet the associated challenges.

Impact

• Increase reliability and safety while reducing errors through best practices and guidelines for transmission and delivery (T&D) switching.

• Reduce worker productivity losses via implementation of appropriate switching procedures that include effective safety elements.

• Promote sharing of lessons learned among peers.

• Develop best practices and new methods via comparisons of current practices.

• Enable an open exchange of information on incidents and findings among participants via the annual power switching safety and reliability conference.

Reports produced by this project serve as industry benchmarks that individual utilities can use to gauge their own performance. Studies of industry “best practices” identify weaknesses and vulnerabilities within

procedures being used and provide guidance for improvements and development of error-insensitive procedures. The project also sponsors the annual Switching Safety and Reliability Conference that provides an opportunity for managers, supervisors, and operations personnel to exchange information about switching policies and procedures that contribute to improved safety and reliability. The conference is open to all interested parties.

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2010 Products

Completion Date Product Type Recommendations for certification of switching personnel: This project

is a culmination of past research on industry practices and procedures for certification of switching personnel. It identifies the most common requirements and skills needed for certification and identifies a feasible certification process. It also evaluates the merits of industry-wide certification versus utility-level or regional certification and suggests the possible profile of a certification agency.

Switching Fundamentals Guide and Training Manual: The EPRI Power

Switching Safety and Reliability project has produced more than 25 valuable reports on this subject matter. Reports evaluate procedures for establishing error-preventing barriers, provide examples of errors and near-misses and derive "lessons learned", address situation awareness and human

performance issues, and contain training materials. This project will complete consolidation of the various elements from previous reports into a

comprehensive switching procedures guide and training manual. The guide and manual will be reviewed every few years as new materials become available.

Communication between field personnel and control center - Utility practices: Communication between field personnel and control center

personnel is often a major cause or contributor to switching errors and near-misses. This project completes a multi-year study of the subject, presents examples of communication that can lead (or has led) to errors, proposes measures to prevent communication errors, and proposes error-immune communications procedures. The results of this project can be used by utilities to gauge their performance against common industry practices.

Identifying error-likely situations in power switching: This project will

analyze know incidents and near-misses and will derive "lessons learned" with the goal of identifying situations and indicators of impending errors in power switching. This information will be used to devise means of preventing the occurrence of such dangerous situations, and in training personnel dealing with power switching.

Database of incidents and near-misses in switching: This is an ongoing

project that collects information on and reports of incidents and near-misses in power switching. A reporting template developed in 2008 is used to gather the essential information. The searchable database will be populated annually with new available information.

Annual conference on switching safety and reliability: The conference is

an opportunity for managers, supervisors, and operations personnel to exchange information about switching policies and procedures that contribute to improved safety and reliability. The conference addresses issues ranging from detailed switching procedures and associated software, through programs for training, audits, and incident investigation, to management strategies and policies.

The annual conference has proven to be a great success and attracts more than 150 participants annually. It will remain a continuing part of the project.

12/31/10

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Completion Date Product Type Annual conference on switching safety and reliability: The conference is

an opportunity for managers, supervisors, and operations personnel to exchange information about switching policies and procedures that contribute to improved safety and reliability. The conference addresses issues ranging from detailed switching procedures and associated software (through programs for training, audits, and incident investigation) to management strategies and policies.

The annual conference has proven to be a great success and attracts more than 150 participants annually. It will remain a continuing part of the project.

12/31/11

Database of incidents and near-misses in switching: This is an ongoing

project that collects information and reports on incidents and near-misses in power switching. A reporting template developed in 2008 is used to gather the essential information. The searchable database will be populated annually with new information.

Switching Fundamentals Guide and Training Manual: The EPRI Power

Switching Safety and Reliability project has produced more than 25 valuable reports on this subject matter. Reports evaluate procedures for establishing error-preventing barriers, provide examples of errors and near-misses and derive "lessons learned," address situation awareness and human

performance issues, and contain training materials. This project will complete consolidation of the various elements from previous reports into a

comprehensive switching procedures guide and training manual. The guide and manual will be reviewed every few years as new materials become available.

Identifying error-likely situations in power switching: This project will

analyze known incidents and near-misses and will derive "lessons learned" with the goal of identifying situations and indicators of impending errors in power switching. This information will be used to devise means of preventing the occurrence of such dangerous situations and in training personnel dealing with power switching.

PS37F Circuit Breaker Life Management (058485)

This project set represents an area of growth for the substations program. In previous years, the work scope was limited and focused. However, second only to transformers, circuit breakers represent the most critical investment for utilities, and their use involves associated maintenance and operation responsibilities. Research under this project set provides utilities with better capabilities in managing these critical assets in the areas of investment decision-making, increased reliability, reduced failures, safer operating practices, reduced maintenance costs, and extended component life. This project set contains two projects. The first focuses on circuit breaker condition assessment and life extension. The second considers the opportunities presented by advances in metering and protection equipment to provide much-needed circuit breaker monitoring and diagnostic functions.

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P37.012 Circuit Breakers Condition Assessment and Life Extension

This project assesses the life-cycle performance of power circuit breakers which is, to a large degree, determined by the performance of constituent materials and components such as seals and o-rings as well as lubricants, compressors and hydraulic systems.

P37.013 Using Relays and Metering Data for Circuit Breaker Diagnostics

Microprocessor protective relays already installed for fault protection are connected to signals from circuit breakers, and can monitor the operation of breakers in normal service. The relays include AC measurements and programmable logic that can be configured to detect operating or timing problems and to flag breakers for maintenance attention before a breaker failure. Project P37.013 investigators are cataloging the specific breaker problems and detection methods, developing the breaker and system programming, and working with utility participants on practical challenges of

deployment across fleets of relays and breakers. When developed, these diagnostic tools also support performance information gathering for breaker population asset management.

P37.012 Circuit Breakers Condition Assessment and Life Extension (058562)

The life-cycle performance of power circuit breakers is, to a large degree, determined by the performance of constituent materials and components. Some deterioration (e.g., linkages and interrupter) is not time dependent, while the rate of deterioration of lubricants and seals is. Together these elements drive the requirements for maintenance and refurbishment. Despite the importance of these issues, utilities have little quantifiable data or a complete understanding of breaker material and sub-system performance to enable cost-effective methods for instituting condition-based maintenance or selecting work practices and tasks. Approach

To address these needs, this project will undertake the following:

Characterization and aging of lubricants, O-rings, seals, and gaskets:

• Collect and analyze samples of greases, oils, and hydraulic fluids to determine degradation and effective life

• Collect and analyze field-aged samples of circuit breaker components

• Catalogue examples and/or samples of utility lubrication related problems or parts failures • Define and quantify HVCB lubrication technical issues

• Characterize possible consequences on breaker performance of degraded lubricants (e.g., slow trip, abnormal mechanism wear, compressor/pump failures)

• Characterize old grease, mixed grease, and dirty grease

Assessment of industry best practices: Gather information about current practices for lubrication of power circuit breaker mechanisms and equipment such as compressors, pneumatic and hydraulic systems, control relays, and switches

Combine knowledge gained about circuit breaker and disconnect switch lubrication into the following:

• A quantitative understanding of aging and deterioration rates.

• Expected life of circuit breaker component materials and subsystems.

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Impact

• Avoid capital investment for replacement breakers via more effective maintenance of existing assets. • Increase reliability through improved circuit breaker operations as a result of enhanced maintenance

effectiveness and better condition assessment. How to Apply Results

Project funders can use project results to implement more effective circuit breaker maintenance programs. 2010 Products

Completion Date Product Type Report on power circuit breaker components and sub-system

degradation modes: This product will summarize results of ongoing

research and outline a living development plan to investigate and understand degradation further. It will form the foundation of high voltage circuit breaker fleet management that will be developed.

Field Guide: HVCB Component Degradation Condition Assessment – O-Rings, Seals and Gaskets: This product will provide guidance on

techniques for condition and degradation assessment of field aged o-rings, seals, and gaskets.

Field Guide: HVCB Component Degradation Condition Assessment – Pumps, Compressors and Control Valves: This product will provide

guidance for recognizing and quantifying performance issues with pumps, compressors and control valves, and maintenance improvement for addressing these issues.

New Versions of HVCB Lubrication Field Guide: Existing versions of this

guide focus on general guidance for the application and removal of lubricants, with member feedback on their effectiveness. New versions will help members select of the proper lubricant for specific applications, components, and sub-systems. Over time, guidance for disconnect switches will also be incorporated.

Completion Date Product Type Report on power circuit breaker components and sub-system

degradation modes: This deliverable will summarize results of ongoing

research and outline a living development plan to investigate and understand degradation further. It will form the foundation of high voltage circuit breaker fleet management that will be developed.

New Versions of Pictorial Field Guides - Power circuit breaker

component degradation assessment and testing 12/31/11

Technical Update

New Versions of HVCB Lubrication Field Guides 12/31/11 Technical

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P37.013 Using Relays and Metering Data for Circuit Breaker Diagnostics (060478)

The widespread use of microprocessor-based protective relays has led to interest in better understanding a number of issues related to their possible application for circuit breaker condition monitoring and maintenance such as the following:

• Practical benefits and limitations of programming relays for diagnosis and reporting or alarming of circuit breaker condition. How helpful is relay data for discovering breaker malfunctions requiring maintenance and for gathering breaker population performance information for asset management?

• Ability to communicate useful diagnostic data, either raw or processed by relay programming, from typical transmission and delivery (T&D) substations.

• How to process communicated relay data into maintenance work orders and asset management extracts. • Practical challenges in deploying relay program templates for breaker diagnosis and in accessing and

using collected data and results. Approach

The focus of this project is to combine knowledge of circuit breaker diagnostics, characteristics, and malfunctions with understanding of analytic capabilities of microprocessor relays already connected for protection tasks, to develop a seamless approach to breaker diagnostics and maintenance. The practical breaker diagnostic tools comprise a combination of programming in relays and data gathering by

communications with relays.

Prior research on breaker diagnostics with relay data included the following: • Relay vendor engagement to document relay capabilities.

• Analysis and listing of breaker malfunctions and detection methods using in-service relay data, as compared to existing off-line maintenance diagnostic tests.

• Planning with selected EPRI members on practical easy-to-implement diagnostic techniques and beginning proposals and discussions of field demonstrations of those techniques.

• Gathering of utility field experience data and views through seminars and meeting discussions. The ongoing 2009 research program includes the following:

• Using the listing of malfunctions and detection methods to develop logic and measurements for programming in microprocessor relays.

• Assessing the suitability of individual diagnostics for inclusion in first field demonstrations with participating members.

• Developing relay logic setting templates and a design for reporting or gathering diagnostic results and alarms, working with participating members.

• Conducting lab tests of circuit breaker diagnostic logic programmed in relays, and communications of diagnostic results.

• Beginning steps toward field deployment and commissioning across selected relay fleets at target utilities. • Gathering experience-based inputs from circuit breaker manufacturers on breaker problems that relays

can diagnose.

• Gathering any new utility field reports on breaker diagnostic experience.

• Creating a project report documenting work program, relay logic and programming, test results, and field deployment and field test plans.

• Continuing to report on North American Electric Reliability Corporation (NERC) PRC-005-02 development – Protection system condition-based maintenance opportunities and strategies leading to the reduction or elimination of time-based maintenance activities for relays and associated equipment. This separate but closely related task carries on in parallel with circuit breaker diagnostic work.

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The 2010 proposed research program includes the following:

• Deploying logic templates and breaker condition reporting tools to the field in relay fleets of participating utilities.

• Commissioning installations and integrating alarms and report gathering.

• Analyzing initial results from the circuit breaker fleet and adjusting settings to distinguish reportable timing or performance issues of breakers.

• Collecting results of relay-based maintenance programs, including feedback from utility field engineering and maintenance staff.

• Creating a project report that documents the available field experience and results, and recommends further steps with utilities and vendors.

• Developing a knowledge base or field guide for circuit breaker diagnostics using relay data. This effort's timing depends on level of project support, implementation progress, and available results.

• Continuing to report on impact and opportunities or NERC PRC-005-2 as described above for 2009 work. This will continue as a major industry focus topic with impact and absorption issues for years to come. Impact

Using the programmability and breaker diagnostics in relays and integrating this capability with maintenance programs as proposed in this ongoing project may offer the following:

• Improved breaker reliability via repairs carried out before breaker failures.

• Appropriate population maintenance program development, focusing field crew efforts on real problems and reducing unneeded maintenance.

• Improved utilization of installed assets (for example, modern protective relays have an innate monitoring capability, which is not widely used today).

• Support of a business case for replacement of aging electromechanical relay populations with modern, programmable microprocessor relays.

• Advances in design features of relays for breaker diagnostics, leading to easier and better field implementations at utilities.

Project funders can directly use or adapt tools and logic templates documented in project results to create practical implementations of breaker problem diagnosis and reporting with their own microprocessor relays. With these tools, they can more efficiently and effectively maintain breaker fleets, utilizing the value of capital investment in relays already installed nearby.